Field of the Invention

The present invention relates to the field of modular frame and shelving

assemblies.

Background of the Invention

Shelf assemblies are particularly advantageous for displaying goods for sale in commercial settings, and are also useful for storing items in closets, garages, and the like. Modular type shelving units have gained popularity for their versatility. This type of shelving allows for a near unlimited number of shapes and sizes to be constructed, while minimizing the amount of inventory that needs to be kept on hand.

Summary of the Invention

According to one aspect of the invention, there is provided a modular frame assembly. The assembly comprises a plurality of supports, and a connector for interconnecting the supports.

According to another aspect, the connector may comprise a base member; and a plurality of legs extending outward from the base member, each leg forming a male coupling configured to connect with a female coupling on the support; wherein each leg includes a resilient member that is deformed when the leg is coupled with the support. According to another aspect, the assembly may further comprise a sleeve configured to be slidably mounted over the support. A shelf support may be mounted to the sleeve. The shelf support may comprise a post normal to an upper face of the shelf support. According to a further aspect, there is provided a connector. The connector comprises a base; a plurality of legs extending outwardly from the base, each leg defining a plug having an exterior surface that has a generally constant profile throughout the length of the leg; and_a member that is movable between an engaged position that projects interiorly of the exterior surface and a disengaged position that is flush with the exterior surface, the member being biased to the engaged position.

According to a further aspect, the outer surface of the resilient member may have a gripping element, and the gripping element may extend outward from the face of the leg. The gripping element can be a barb. In another embodiment, the modular frame assembly may further comprise a mounting bracket. The mounting bracket comprises a longitudinal member, which includes a cuff along the length of a first side that slidably engages the support, and a track along the length of a second side.

The modular frame assembly may include an adjustable shelf bracket, the adjustable shelf bracket comprises a shelf bracket face; a brace plate extending downwardly forming a generally cantilevered structure; and at least one guide connected to the brace plate that is received by the track.

According to a further aspect, there is provided a kit for constructing a frame assembly, the kit comprising a plurality of supports, and a connector for

interconnecting the supports. The kit may also comprise a shelf support, a mounting bracket, and/or an adjustable shelf bracket. Brief Description of the Drawings

In the drawings:

Figure 1A is a perspective view of an assembly according to an embodiment of the invention;

Figure IB is an exploded view of the assembly shown in Figure 1A;

Figure 1C is a partial exploded view of segment A from Figure IB;

Figure 2 is a perspective view of a connector according to an embodiment for use in the assembly;

Figure 3A is a top view of the connector shown in Figure 2;

Figure 3B is a section view of the connector along line F-F in Figure 3A;

Figure 4 is a perspective view of the connector shown in Figure 2;

Figure 5 is a perspective view of the connector shown in Figure 2;

Figures 6A to 6N are perspective views of connectors according to different embodiments of the invention;

Figure 7A is a top partial view of an assembly according to an embodiment;

Figure 7B is a section view along line P-P in Figure 7A;

Figure 7C is an enlarged view of segment W from Figure 7B;

Figures 8A-8D are perspective views of a shelf support according to an embodiment for use in the assembly;

Figure 9 is a perspective view of a shelf support according to another embodiment;

Figure 10 is a perspective view of a shelf support according to another

embodiment; Figure 11 is a perspective view of a shelf support according to another embodiment;

Figure 12A is a perspective view of a right shelf bracket according to an

embodiment for use in the assembly;

Figure 12B is a perspective view of a left shelf bracket according to another embodiment;

Figure 12C is a perspective view of a shelf support according to yet another embodiment;

Figure 13A is a top perspective view of a corner connector with shelf support according to an embodiment;

Figure 13B is a bottom perspective view of the corner connector with shelf support shown in Figure 13A;

Figure 14A is a perspective view of a shelf support bracket according to another embodiment;

Figure 14B is a perspective view of a shelf support bracket according to another embodiment;

Figure 15A is a top perspective view of a shelf support riser according to an embodiment;

Figure 15B is bottom perspective view of the shelf support riser shown in Figure 15A;

Figure 15C is a perspective view of a shelf support riser engaged with a shelf support according to an embodiment of the invention;

Figure 16A is a partial view of an assembly according to an embodiment;

Figure 16B is an exploded view of the assembly shown in Figure 11A; Figure 17A is a top partial view of an assembly according to an embodiment;

Figure 17B is a section view along line K-K of Figure 12A;

Figure 17C is an enlarged view of segment M from Figure 12B;

Figure 18 is a perspective view of a mounting bracket according to an embodiment for use in the assembly;

Figure 19 is a perspective view of a shelf bracket according to an embodiment;

Figure 20 is a view of a mounting bracket and a shelf bracket on a support;

Figure 21A is a section view of a mounting bracket and a shelf bracket on a support;

Figure 21B is a section view of a mounting bracket and a shelf bracket on a support;

Figure 22A is a perspective view of a miter connection between two supports according to an embodiment;

Figure 22B is an exploded view of the miter connection shown in Figure 22A;

Figure 22C is a section view of the miter connection shown in Figure 22A;

Figure 23A is a partial view of an assembly according to an embodiment;

Figure 23B is a partially exploded view of Figure 23A, showing a foot cap;

Figure 23C is a section view of the partial assembly shown in Figure 23A;

Figure 24A is a partial view of an assembly according to an embodiment;

Figure 24B is a partially exploded view of Figure 24A, showing a foot;

Figure 24C is a section view of the partial assembly shown in Figure 24A; Figure 25A is a partial view of an assembly according to an embodiment including a caster adaptor;

Figure 25B is a section view of the partial assembly shown in Figure 25A;

Figure 26A is a front perspective view of a capped caster adapter;

Figure 26B is an exploded view of the caster adapter of Figure 26A;

Figure 26C is back perspective view of the caster adapter of Figure 26A;

Figure 27A is a perspective view of a corner joint from an assembly according to an embodiment;

Figure 27B is a partially exploded view of Figure 27A, showing fasteners that secure supports to a connector;

Figure 27C is a section view of the corner joint shown in Figure 27A;

Figure 28A is a partial view of an open shelving from an assembly according to an embodiment;

Figure 28B is a partially exploded view of the open shelving shown in Figure 28A;

Figure 29A is a partial view of an open shelving from an assembly according to another embodiment;

Figure 29B is a section view of the open shelving shown in Figure 29A;

Figure 29C is an exploded view the open shelving shown in Figure 23A; and

Figures 30 to 49 are views of various assemblies according to further embodiments of the invention. Detailed Description of the Embodiments

A frame assembly 10 according to an embodiment of the present invention is shown in Figures 1A-C. The assembly 10 includes a plurality of vertical and horizontal supports 14 linked together by connectors 12 to form the frame assembly 10.

Shelving members 16 can be attached or mounted directly or indirectly to the supports 14.

A connector 12 has a base 28, which in Figure 2 to 5 is shown as generally cube- shaped, and legs 30 extend from one or more faces of the base 28.

The supports 14 have a substantially square cross section, providing for four walls 18, an exterior surface 20 and an interior surface 22. The edges 24 of each end defines an opening 26 that is dimensioned to form a female coupling that matingly receives a leg 30 from a connector 12.

Each leg 30 is defined by a plurality of side faces 32 and an end face 34, which define a hollow socket 35 therein. The legs are shaped and dimensioned to form a male coupling that is received by an opening 26 of the support 14. On at least one side face 32 of the leg 30 is a resilient member 36 that is able to flex in response to pressure. The resilient member 36 is a tab defined by a U-shaped void in a face of the leg 30, creating a free end 40. At least one gripping element 38 having a sharp projection, such as a barb, extends outward from the resilient member 36, and is preferably located near the free end 40 of the resilient member 36.

The resilient member 36 is biased to be in a first position, in which it is substantially planar with the face of the leg 30 (see e.g. Figures 3B). When the leg 30 is received by a support 14 as shown in Figure 7B, the interior surface 22 of the support 14 applies pressure to the resilient member 36 through contact with the gripping element 38. This pressure moves the resilient member 36 into a second position, in which the free end 40 of the resilient member flexes inward (see e.g. Figure 7C). While the resilient member 36 is in the second position, the gripping element 38 no longer serves as an impediment, and the support 14 can slide over the leg 30.

Once the leg 30 has been received by the support 14, the gripping element 38 engages with the interior surface 22 of the support 14. The engagement of the gripping element 38 with the interior surface of the support 14 creates resistance to the removal of the support 14 from the leg 30 of the connector 12, thereby coupling the support 14 to the connector 12.

The leg 30 has a smaller perimeter than the face of the base 28 from which it extends, which creates an abutment 42. When a leg 30 is received by a support 14, the edges 24 from the support 14 approach or contact the abutment 42, creating a substantially flush connection between the base 28 and the support 14.

After the support 14 has been placed over the leg 30, a fastener 43 can be used to further secure the support 14 to the connector 12 (see e.g. Figures 27A-27C). The fastener can be received by a hardware aperture 44 in a leg 30 of the connector 12. A corresponding aperture 45 can also be present in the support 14.

As can be seen in Figures 6A - 6K, legs 30 extend from one or more faces of the base 28, depending on what role the connector 12 will have in the assembly 10.

For example, Figures 6A-6C illustrate a corner connector 12; Figures 6D and 6E illustrate middle connectors 12; Figures 6F-6H illustrate central connectors 12, which would be located in the interior of an assembly 10; Figure 6J illustrates connector 12 that can longitudinally connect two supports 14; and Figure 6K illustrates a connector 12 having a single leg 30 extending from the base, which would primarily be used as a plug to cap an open end of a support 14.

The base of connectors 12 that are to form the lower level of the assembly 10, such as those shown in e.g. Figures 6A to 6E, may include a caster aperture 46 to receive and secure a caster wheel (not shown). In addition, the plug shown in Figure 6K may also have a caster aperture 46 as can be seen in Figure 26B. Installing the plug into the bottom of a foot support will allow the installation of caster wheels onto the structure (see Figures 25A-B). A cap 47 (Figures 6N and 26A-B) can be used to cover the caster aperture 46 by way of e.g. a snap fit.

Figures 6L and 6M illustrate types of feet that can be used in the assembly 10.

Each foot is defined by side walls and an end wall having an opening on one end. The dimensions between the feet shown in Figures 6L and 6M differ based on the intended use of the feet.

The foot shown in Figure 6L is further shown in Figures 24A-24C, in which it can be seen that it defines a hollow interior having an open end and a closed end. The foot engages with the leg of the connector as shown in Figure 24B. The foot shown in Figure 6M defines a hollow interior having an open and a closed end. However, this foot is dimensioned to engage with and receive the end of a support 14 as can be seen in Figures 23A-23C.

The assembly 10 may include a shelf support 48 (see Figures 8 to 11). The shelf support 48 includes a collar 50 that is dimensioned to snugly fit around the perimeter of a support 14. A sleeve 52 extends downward from at least one side of the collar 50. Connected to the collar 50 are a plurality of shelf support ribs 54 that interconnect to collectively define a seat 56. Struts 55 connect the underside of the shelf support ribs 54 to the sleeve 52 creating a generally cantilevered structure.

The shelf support ribs 54 define an upper face of the seat 56 receives a shelving member 16. At least one post 58, having a pointed tip 60, extends upwardly from the face of the seat 56. As can be seen in Figures 17B-17C, when a shelving member 16 is placed on the seat 56, the pointed tip 60 of the post 58 pierces the underside of the shelving member 16, and aids in securing the shelving member 16 in place. Figures 16A-16B illustrate a shelf support 48 in use in the assembly 10, in which the collar 50 is placed over the vertical support 14. When a shelving member 16 is placed on the seat, a portion of the weight from the shelving member 16 is transferred through the struts 55 and sleeve 52 to the vertical support 14.

The shape and dimension of the seat 56 may take a number of forms relating to the nature and intended use of the shelf support 48. Figures 8A-8D illustrate a corner shelf support 48, in which the sleeve 52 extends downward from two sides of the collar 50 and the shelf support ribs 54 extend from same two sides of the collar 50 to form the seat 56.

Figure 9 illustrates a double-sided shelf support 48, in which the sleeve 52 extends downward from three sides of the collar 50 and the shelf support ribs 54 extend from same three sides of the collar 50 to form the seat 56.

Figure 10 illustrates a central shelf support 48, in which the shelf support ribs 54 extend from all sides of the collar 50. In this embodiment, the sleeve 52 extends downward from all sides of the collar 50 and the shelf support ribs 54 extend from all sides of the collar 50 to form a seat 56 that surrounds the collar 50.

Figure 11 illustrates a split corner shelf support 48, which is effectively two opposing corner shelf supports joined together. The sleeve 52 extends downward from all sides of the collar 50, and the ribs 54 form two distinct corner shelf support seats 56 extending from opposing corners of the collar 50.

After the shelving member 16 has been placed on the seat 56, a fastener can be used to further secure the shelving member 16 to the shelf support 48. The fastener can be received by a hardware aperture 57 in the shelf support 48, which may be formed by the shelf support ribs 54. A corresponding aperture (not shown) can also be present in the shelving member 16. Figures 12A to 12C illustrate a shelf bracket 66 for use in the assembly 10. This embodiment of the shelf bracket 66 includes a collar 50 and a sleeve 52 that extends downwardly therefrom. The location of the collar 50 may vary dependent upon if the shelf bracket 66 is intended to support the left side of the shelving member 16 (Figure 12B) or the right side of the shelving member 16 (Figure 12A). The shelf bracket 66 is generally L-shaped forming a cantilevered structure, having a shelf bracket face 70 that is substantially perpendicular with the sleeve 52. A plurality of struts 74 connect the underside of the shelf bracket face 68 and sleeve 52. Alternatively, the shelf bracket 66 may be double-sided as shown in Figure 12C, in which two distinct brackets 66 extend from opposing sides of the collar 50.

Figures 28A-28B show the shelf brackets of Figures 12A and 12B in use within an embodiment of the assembly 10, while Figures 30A and 30B show the shelf bracket of Figure 12C in use within an embodiment of the assembly 10.

Figures 15A and 15B illustrate a riser 80 for use in the assembly 10. The riser 80 has a perimeter structure 82 that defines a shelf-supporting platform. A cross- brace 84 connects a pair of opposing corners. Extending downward from the underside of the riser 80 is a coupling structure 86. The coupling structure 86 is shaped and dimensioned to mate with an underlying component, such as a shelf support 48. For example, the coupling structure 86 is shaped and dimensioned to matingly fit with the riser receiving area 53 of the shelf support 48, which is the void space defined by the shelf support ribs 54. The coupling structure 86 attaches to the riser receiving area 53 of the shelf support 48 by e.g. a snap-fit means as can be seen in Figure 15C. The riser 80 may have at least one post 58 having a pointed tip 60 that extends upwardly from the face thereof. The riser 80 may have a fastener aperture 88 that allows the riser 80 to be secured via a fastener to an underlying component. For example, when the riser 80 is installed on a shelf support 48, the fastener aperture 88 aligns with the hardware aperture 57. Figures 29A-29C show the riser 80 in use within an embodiment of the assembly 10. The assembly 10 may include a mounting bracket 62 as shown in Figure 18. The mounting bracket 62 is shaped and dimensioned to snugly yet slidably engage with a vertical support 14. The mounting bracket 62 maintains its position on the vertical support 14 with a friction fit. Figure 19 shows an adjustable shelf bracket 66 that couples with the mounting bracket 62 to provide further shelf support. The shelf bracket 66 is generally L- shaped forming a cantilevered structure, having a shelf bracket face 70 and a brace plate 72 that are substantially perpendicular with each other. At least one guide 76 is connected to the brace plate 72. A plurality of struts 74 connect the shelf bracket face 68 and the brace plate 72.

The mounting bracket 62 includes sides 63 that define a cuff 65 that slidably engages a support 14, and the opposing side of the mounting bracket 62 has a track 64 that receives the adjustable shelf bracket 66. The track 64 has internal channels 70 on opposing sides thereof. The guides 76 from the shelf bracket 66 are placed in the channels 70 allowing the shelf bracket to move up and down the track 64 (see Figure 20).

The shelf bracket 66 has securing members 78, such as hooks, extending from the brace plate 72. When the shelf bracket 66 is in a desired position, the securing 78 members engage with corresponding slots 68 that are located inside the track 64 (see Figure 21B). The shelf bracket 66 is now secured within the mounting bracket 62 (see Figure 21A), and is able to support e.g. a shelving member 16. Figures 32A and 32B show the mounting bracket 62 and shelf bracket 66 in use within an embodiment of the assembly 10.

Although a specific embodiment is herein shown and described, variations are possible. The supports can be made of wrapped paper fibre but other materials can also be used, such as extruded plastic. The exterior of the support can be painted or powder coated. The powder coating increases stiffness and improves moisture resistance. The supports can also be impregnated with resin to improve rigidity and moisture resistance. The supports can be wrapped with printed vinyl graphics, which can contribute to their visual appeal, and also improves moisture resistance Tubes can also be produced from extruded plastic.

Connectors can be moulded in various colours and textures. Acrylonitrile butadiene styrene (ABS) is the preferred plastic but other plastics can be utilized, including fibre reinforced plastics. The connectors can also be vacuum metalized.

The shelving members can be made from a variety of materials, including honeycomb paper board, wood, laminate, corrugate, MDF or plastic.

The base of the connector may be substantially planar with only two opposing faces. In this embodiment as shown in Figure 6H, there are two legs extending outwardly in opposing directions that can couple two longitudinal supports 14. Alternatively, this planar base may have only a single leg extending outward see Figure 61, which would serve as a cap on an open end of a support 14.

Figures 13A and 13B show a hybrid connector 12 with a shelf support 48. This corner connector 12 has two legs extending outward from a base 28. The base 28 is "L" shaped, with each length of the base 28 being equivalent in dimension. The legs of the connector are generally as discussed above. Connected to the interior corner of "L" shape of the base 28 is a shelf support 48. The shelf support 48 includes shelf support ribs 54 that define a seat 56 to support a shelving member 16. The shelf support ribs also define riser receiving areas 53 that can receive coupling structures 86 from a riser 80. Figures 14A and 14B show another embodiment of the shelf support bracket 66 for handling lighter loads. This embodiment includes a collar 50 connected with either a single-sided (Figure 14A) or double-sided (Figure 14B) supporting member 67.

Figures 22A to 22C show another embodiment that can be incorporated into the assembly of the present invention. The Figures show a miter connection between two supports 14. The connector 12 is a corner connector 12 generally having the features as discussed above. However, there is no abutment 42. Rather, the legs 30 have the same exterior dimension as the base 28. The supports 14 have a miter cut, and slide over the whole of the connector 12. The supports 14 abut each other, hiding the connector 12 from view.

In addition, the modular nature of the assembly 10 makes it versatile, with the ability to construct a number of structures, such as retail displays, trade show booths, pop up stores, furniture (tables, book cases, shelving), retail display fixtures, retail signage (sign frames), and the like. Figures 30 to 49 illustrate some exemplary assemblies that can be built with combinations of the components as described above. On this basis, any combination of the components as described above can be included in an unassembled state and sold in a kit. A kit comprising some combination of the components, such as a plurality of connectors 12 and supports 14, will allow the end user to create the desired assembly 10.